Acoustic profile recognition for discriminating between hazardous emissions and non-hazardous emissions

ABSTRACT

A method for classifying an emission includes generating a first acoustic profile at a first acoustic sensor; generating a second acoustic profile at a second acoustic sensor; comparing the first acoustic profile to a first reference acoustic profile to generate a first difference; comparing the second acoustic profile to a second reference acoustic profile to generate a second difference; and classifying the emission as one of a hazardous emission or a non-hazardous emission in response to the first difference and the second difference.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/285,718, filed Oct. 5, 2016, which claims the benefit of and priorityto U.S. Provisional Patent Application Ser. No. 62/238,884, filed Oct.8, 2015, the entire contents of which are incorporated herein byreference.

BACKGROUND

The present disclosure relates generally to leak detection, and inparticular, to use of acoustic profile recognition in discriminatingbetween hazardous emissions and non-hazardous emissions.

Acoustic technology for detection of leaks (e.g., gas leaks) inhazardous locations has been commercially available for over a decade.Much of the advancement with acoustic leak detection has been focused ondiscriminating between an actual gas leak and potential false sources ofacoustic noise in the frequency range of interest (e.g., ultrasonicfrequencies). While conventional acoustic detection can provide verygood discrimination between pressurized gas leaks and false positives,there is a real and un-met industry need to provide discriminationbetween hazardous emissions and non-hazardous emissions. A non-hazardousemission may be an escape of pressurized gas that occurs during normalplant operations or as part of maintenance, start-up, or shut downprocedures. Sources of non-hazardous emission can be overpressurevalves, flare stacks, shop air and emergency shutdown release. Thesenon-hazardous emissions are actual pressurized gas escapes, can be verylarge in magnitude, and will be detected as an alarm condition byconventional acoustic detectors. Ideally, an acoustic detector would beable to distinguish between hazardous and non-hazardous emissions,however common practice is to either increase the alarm threshold, orphysically move the detector away from the source of the non-hazardousemission to avoid an alarm. Both of these practices de-sensitize thedetector to hazardous emissions in the same vicinity. Also, some of thenon-hazardous emissions can be of significant duration, making theadjustment to a longer alarm time threshold impractical.

SUMMARY

In one embodiment, a method for classifying an emission includesgenerating a first acoustic profile at a first acoustic sensor;generating a second acoustic profile at a second acoustic sensor;comparing the first acoustic profile to a first reference acousticprofile to generate a first difference; comparing the second acousticprofile to a second reference acoustic profile to generate a seconddifference; and classifying the emission as one of a hazardous emissionor a non-hazardous emission in response to the first difference and thesecond difference.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the first acousticprofile comprises measured sound pressure levels across a plurality offrequencies.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the firstdifference comprises a root mean square error.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the emission isdetermined to be hazardous if either (i) the first difference is greaterthan a first threshold or (ii) the second difference is greater than asecond threshold.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the gas emissionis determined to be non-hazardous if both (i) the first difference isless than a first threshold and (ii) the second difference is less thana second threshold.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the firstthreshold and the second threshold are the same.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein generating thefirst difference occurs at the first acoustic sensor.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the first acousticsensor transmits the first difference to a controller.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein generating thesecond difference occurs at the second acoustic sensor.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the secondacoustic sensor transmits the second difference to a controller.

In another embodiment, a system for classifying an emission includes afirst acoustic sensor to generate a first acoustic profile; a secondacoustic sensor to generate a second acoustic profile; a controller incommunication with the first acoustic sensor and the second acousticsensor over a network; the controller classifying the emission as one ofa hazardous emission or a non-hazardous emission in response to a firstdifference between the first acoustic profile and a first referenceacoustic profile and a second difference between the second acousticprofile and a second reference acoustic profile.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the first acousticsensor generates the first difference and transmits the first differenceto the controller and the second acoustic sensor generates the seconddifference and transmits the second difference to the controller.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein controllergenerates the first difference and the second difference.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the first acousticprofile comprises measured sound pressure levels across a plurality offrequencies.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the firstdifference is a root mean square error.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the emission isdetermined to be hazardous if either (i) the first difference is greaterthan a first threshold or (ii) the second difference is greater than asecond threshold.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the gas emissionis determined to be non-hazardous if both (i) the first difference isless than a first threshold and (ii) the second difference is less thana second threshold.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the firstthreshold and the second threshold are the same.

In addition to one or more of the features described above, or as analternative, further embodiments may include, wherein the network is awireless network.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. However, it should be understood that the followingdescription and drawings are intended to be exemplary in nature andnon-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features will become apparent to those skilled in the art fromthe following detailed description of the disclosed non-limitingembodiments. The drawings that accompany the detailed description can bebriefly described as follows.

FIG. 1 depicts an environment for implementation of an exemplaryembodiment;

FIG. 2 depicts a system for discriminating between a hazardous emissionand a non-hazardous emission in an exemplary embodiment;

FIG. 3 depicts a method of training acoustic sensors in an exemplaryembodiment; and

FIG. 4 depicts a method of discriminating between a hazardous emissionand a non-hazardous emission in an exemplary embodiment.

DETAILED DESCRIPTION

FIG. 1 depicts an environment 8 for implementation of an exemplaryembodiment. Exemplary embodiments use acoustic sensors to distinguishbetween a hazardous emission (e.g., a gas leak) and a non-hazardousemission (e.g., gas release at an overpressure relief valve). Shown inFIG. 1 is an exemplary facility including a potential source of ahazardous emission 10. In the example in FIG. 1, the potential source ofa hazardous emission 10 is a pipe carrying pressurized gas, but it isunderstood that potential sources of hazardous emission may include awide variety of components. Also, shown in FIG. 1 is a source ofnon-hazardous emission 12. In the example in FIG. 1, the source of anon-hazardous emission 12 is pressure relief valve, but it is understoodthat potential sources of non-hazardous emission may include a widevariety of components.

Also shown in FIG. 1 are acoustic sensors 16 and 18. A first acousticsensor 16 is located at a first position and a second acoustic sensor 18is located at a second position, different from the first position.Although only two acoustic sensors 16/18 are shown in FIG. 1, it isunderstood that embodiments may utilize any number of acoustic sensors,and embodiments are not limited to two acoustic sensors.

During operation, each acoustic sensor 16/18 continually generates anacoustic profile. The acoustic profile represents sound pressure level(SPL) across a number of frequencies. In an exemplary embodiment, theSPL is measured across frequencies in the ultrasonic range (e.g., 20 kHzto 80 kHz), but it is understood that SPLs may be measured across adifferent range of frequencies. If the sensed acoustic profile indicatesa potential alarm, the sensed acoustic profile is compared to arespective reference acoustic profile to distinguish an emission aseither hazardous (e.g., a gas leak) or non-hazardous (e.g., a pressurerelief valve).

FIG. 2 depicts a system for discriminating between a hazardous emissionand a non-hazardous emission in an exemplary embodiment. The acousticsensors 16/18 are shown connected to a network 30. The network 30 may bea wired, wireless, or combination wired/wireless network. The network 30provides for bidirectional communication between a controller 34 and theacoustic sensors 16/18. Acoustic sensor 16 may include a processor 17(e.g., a general purpose microprocessor) that performs operations inresponse to software/firmware stored in a memory. The processor 17 canbe any type or combination of computer processors, such as amicroprocessor, microcontroller, digital signal processor, applicationspecific integrated circuit, programmable logic device, and/or fieldprogrammable gate array. Acoustic sensor 16 also includes acommunications interface 19 (e.g., a network card or chip) for enablingcommunications over network 30. Acoustic sensor 18 may be similarlyconstructed, and may include a processor 20 and communication interface21.

The controller 34 may include a processor 35 (e.g., a general purposemicroprocessor) that performs operations in response tosoftware/firmware stored in a memory. The processor 35 can be any typeor combination of computer processors, such as a microprocessor,microcontroller, digital signal processor, application specificintegrated circuit, programmable logic device, and/or field programmablegate array. The controller 34 also includes a communications interface36 (e.g., a network card or chip) for enabling communications overnetwork 30. The controller 34 interfaces with the acoustic sensors 16/18and an alarm monitoring system 38. The controller 34 may be incommunication with alarm monitoring system 38 over wired connection,wireless connection, or combination wired/wireless connection.

In order to detect non-hazardous emissions in the environment 8, theacoustic sensors 16/18 are operated in a training mode to generate areference acoustic profile for one or more sources of non-hazardousemission. FIG. 3 depicts a method of training the acoustic sensors 16/18in an exemplary embodiment. The training is performed to generate areference acoustic profile for each non-hazardous emission at eachacoustic sensor 16/18. These reference acoustic profiles are then usedto discriminate between a hazardous emission and a non-hazardousemission.

The training mode begins at 100, where the acoustic sensors 16/18 areplaced in a training mode. This may be performed by controller 34sending a command to the acoustic sensors 16/18 to enter a trainingmode. Once the acoustic sensors 16/18 are in training mode, flowproceeds to 104 where the non-hazardous emission is activated. This mayinclude, for example, operating an over-pressure relief valve or othersource of non-hazardous emission. At 108, the first acoustic sensor 16generates a first reference acoustic profile. The first referenceacoustic profile includes the SPLs sensed across a plurality offrequencies in response to the non-hazardous emission. The firstreference acoustic profile may be stored in the acoustic sensor 16and/or transmitted to the controller 34. At 112, the second acousticsensor 18 generates a second reference acoustic profile. The secondreference acoustic profile includes the SPLs sensed across a pluralityof frequencies in response to the non-hazardous emission. The secondreference acoustic profile may be stored in the acoustic sensor 18and/or transmitted to the controller 34.

FIG. 4 depicts a method of discriminating between a hazardous emissionand a non-hazardous emission in an exemplary embodiment. The processbegins at 200 where acoustic sensors 16/18 operate to detect a potentialalarm. A potential alarm may be detected when one or both of theacoustic sensors 16/18 detect an SPL that is above the SPL of the normalbackground noise of the environment 8 by some amount. The acousticsensors 16/18 continually monitor the environment 8, and thuscontinually generate acoustic profiles. In an exemplary embodiment, eachacoustic sensor 16/18 monitors a plurality of frequency bands. If apredetermined number of frequency bands (e.g., 14 out of 24) haveexceeded the normal background noise by some dB, then a potential leakis indicated.

If a potential alarm is present, then at 208 a first acoustic profilefrom first acoustic sensor 16 is compared to the first referenceacoustic profile to determine if a first difference between the firstacoustic profile and the first reference acoustic profile is greaterthan a threshold. In an exemplary embodiment, the first acoustic profileis compared to the first reference acoustic profile using a rootmean-square error (MSE) technique. It is understood that othertechniques for comparing the acoustic profiles may be used. At 208, ifthe first difference exceeds a threshold (e.g., 6 db) then flow proceedsto 212, where the emission is classified as hazardous and an alarmcondition is generated.

With a negative outcome at 208, flow proceeds to 210 where the secondacoustic profile is compared to the second reference acoustic profile todetermine if a second difference between the second acoustic profile andthe second reference acoustic profile is greater than a threshold. In anexemplary embodiment, the second acoustic profile is compared to thesecond reference acoustic profile using a root mean-square error (MSE)technique. It is understood that other techniques for comparing theacoustic profiles may be used. At 210, if the second difference exceedsa threshold (e.g., 6 db) then flow proceeds to 212, where the emissionis classified as hazardous and an alarm condition is generated. Thethreshold used at 208 may be the same or different than the thresholdused at 210. With a negative outcome at 210, flow proceeds back to 200.Thus, if both the first difference and the second difference are lessthan the respective thresholds, then an alarm condition is not indicatedas the source of the emission is classified as non-hazardous.

FIG. 4 illustrates generating an alarm condition if either of the firstdifference or the second difference is greater than a threshold. If 3 ormore acoustic sensors are used, then different logic may be used todetermine an alarm condition. In one embodiment, the differences betweenthe respective acoustic profiles and reference acoustic profiles must beless than a threshold for all acoustic sensors to avoid an alarmcondition. In another embodiment, the differences between the respectiveacoustic profiles and reference acoustic profiles must be less than athreshold for a majority of the acoustic sensors to avoid an alarmcondition. Furthermore, individual acoustic sensor thresholds may beadjusted up/down based on the real-time signal strength of the real timeacoustic SPL. For example, sensors closer to background noise may beassigned more error margin, or a larger threshold.

Operations 208 and 210 may be performed at either acoustic sensors 16/18or at the controller 34. In one embodiment, the acoustic sensor 16stores the first reference acoustic profile and the acoustic sensor 18stores the second reference acoustic profile. In operation, thecomparison at 208 between the first acoustic profile and the firstreference acoustic profile is performed by acoustic sensor 16. Theacoustic sensor 16 then transmits an alarm code and the result of thecomparison to the controller 34. The controller 34 can then distinguishbetween a hazardous emission and a non-hazardous emission based on thedifference between the between the first acoustic profile and the firstreference acoustic profile. Similarly, the comparison at 210 between thesecond acoustic profile and the second reference acoustic profile may beperformed by acoustic sensor 18.

If either acoustic sensor 16 or acoustic sensor 18 senses an alarmcondition, an alarm signal is provided to the controller 34 along withthe result of the comparison at operations 208 and 210 (e.g., thedifference in db). The controller may actively poll acoustic sensors16/18 for the difference values upon receiving a potential alarmcondition. This reduces the amount of data transmitted on the network30, as the acoustic sensors 16/18 only transmit the presence of apotential alarm condition and the result of the comparison to thereference acoustic profile, and not the full acoustic profiles.

In other embodiments, the controller 34 stores the first referenceacoustic profile and the second reference acoustic profile. The acousticsensors 16/18 transmit the sensed first and second acoustic profiles tothe controller 34. Controller 34 then performs operations 208 and 210.Regardless of which device performs operations 208 and 210, thecontroller 34 may communicate an alarm condition to the alarm monitoringsystem 38.

In the embodiments described herein, only two acoustic sensors 16/18 areshown, but it is understood that embodiments may use a higher number ofacoustic sensors throughout the environment 8. Each acoustic sensor maystore multiple reference acoustic profiles corresponding to multiplesources of non-hazardous emissions.

Embodiments allow for detection of non-hazardous emissions while stillmaintaining maximum sensitivity. Embodiments discriminate betweenhazardous emissions and non-hazardous emissions without compromisingdetector sensitivity. The system may be customized to each environmentusing the training mode and new source of non-hazardous emissions can beadded at any time to an existing installation through additionaltraining. Low bandwidth communication between the acoustic sensors 16/18and the controller 34 allows for use of a simple wireless network 30.Using multiple acoustic sensors allows for identifying direction and/orlocation of hazardous emissions. Acoustic sensors 16/18 generate uniquereference acoustic profiles, which take into account frequency dependentattenuation through the atmosphere. In this manner, the two acousticsensors are able to distinguish between emissions of varying amplitudesand locations that could mimic a non-hazardous emission.

While the present disclosure is described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the spirit and scope of the present disclosure. Inaddition, various modifications may be applied to adapt the teachings ofthe present disclosure to particular situations, applications, and/ormaterials, without departing from the essential scope thereof. Thepresent disclosure is thus not limited to the particular examplesdisclosed herein, but includes all embodiments falling within the scopeof the appended claims.

What is claimed is:
 1. A method comprising: entering a training modeincluding: generating a non-hazardous emission; at a first acousticsensor at a first location, generating a first reference acousticprofile including sound pressure levels across a plurality offrequencies in response to the non-hazardous emission; at a secondacoustic sensor at a second location, generating a second referenceacoustic profile including sound pressure levels across the plurality offrequencies in response to the non-hazardous emission; exiting thetraining mode; generating a first acoustic profile at the first acousticsensor in response to an emission, the first acoustic profile includingsound pressure levels across the plurality of frequencies; generating asecond acoustic profile at the second acoustic sensor in response to theemission, the second acoustic profile including sound pressure levelsacross the plurality of frequencies; comparing the first acousticprofile to the first reference acoustic profile to generate a firstdifference; comparing the second acoustic profile to the secondreference acoustic profile to generate a second difference; andclassifying the emission as one of a hazardous emission or anon-hazardous emission in response to the first difference and thesecond difference.
 2. The method of claim 1 wherein the first differencecomprises a root mean square error.
 3. The method of claim 1 wherein theemission is determined to be hazardous if either (i) the firstdifference is greater than a first threshold or (ii) the seconddifference is greater than a second threshold.
 4. The method of claim 1wherein the gas emission is determined to be non-hazardous if both (i)the first difference is less than a first threshold and (ii) the seconddifference is less than a second threshold.
 5. The method of claim 4wherein the first threshold and the second threshold are the same. 6.The method of claim 1 wherein generating the first difference occurs atthe first acoustic sensor.
 7. The method of claim 6 wherein the firstacoustic sensor transmits the first difference to a controller.
 8. Themethod of claim 1 wherein generating the second difference occurs at thesecond acoustic sensor.
 9. The method of claim 8 wherein the secondacoustic sensor transmits the second difference to a controller.
 10. Themethod of claim 1 further comprising determining a location of thehazardous emission in response to the first acoustic profile and thesecond acoustic profile.
 11. A system comprising: a first acousticsensor at a first location; a second acoustic sensor at a secondlocation; a controller in communication with the first acoustic sensorand the second acoustic sensor over a network; the system operable toperform: entering a training mode including: generating a non-hazardousemission; at the first acoustic sensor, generating a first referenceacoustic profile including sound pressure levels across a plurality offrequencies in response to the non-hazardous emission; at the secondacoustic sensor, generating a second reference acoustic profileincluding sound pressure levels across the plurality of frequencies inresponse to the non-hazardous emission; exiting the training mode;generating a first acoustic profile at the first acoustic sensor inresponse to an emission, the first acoustic profile including soundpressure levels across the plurality of frequencies; generating a secondacoustic profile at the second acoustic sensor in response to theemission, the second acoustic profile including sound pressure levelsacross the plurality of frequencies; comparing the first acousticprofile to the first reference acoustic profile to generate a firstdifference; comparing the second acoustic profile to the secondreference acoustic profile to generate a second difference; andclassifying the emission as one of a hazardous emission or anon-hazardous emission in response to the first difference and thesecond difference.
 12. The system of claim 11 wherein the first acousticsensor generates the first difference and transmits the first differenceto the controller and the second acoustic sensor generates the seconddifference and transmits the second difference to the controller. 13.The system of claim 11 wherein controller generates the first differenceand the second difference.
 14. The system of claim 11 wherein the firstdifference is a root mean square error.
 15. The system of claim 11wherein the emission is determined to be hazardous if either (i) thefirst difference is greater than a first threshold or (ii) the seconddifference is greater than a second threshold.
 16. The system of claim11 wherein the gas emission is determined to be non-hazardous if both(i) the first difference is less than a first threshold and (ii) thesecond difference is less than a second threshold.
 17. The system ofclaim 16 wherein the first threshold and the second threshold are thesame.
 18. The system of claim 11 wherein the network is a wirelessnetwork.
 19. The system of claim 11 wherein the controller is configuredto determine a location of the hazardous emission in response to thefirst acoustic profile and the second acoustic profile.